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Abstract:

A nonwoven fabric having a surface concavo-convex structure, and a molded
member and a wiping cloth that use the nonwoven fabric are provided. The
nonwoven fabric having a surface concavo-convex structure is formed by
pressing a planar element having a plurality of apertures against at
least one surface of a nonwoven fabric that has been formed by passing
hot air through a web including heat adhesive fibers so as to heat-bond
interlacing points between the fibers. The pressing process is performed
in a state where the nonwoven fabric retains heat in a degree that does
not further promote the heat bonding. The nonwoven fabric having a
surface concavo-convex structure is soft and exhibits high strength and
sufficient resistance against stress.

Claims:

1. A nonwoven fabric having a surface concavo-convex structure, formed by
pressing a planar element having a plurality of apertures against at
least one surface of a nonwoven fabric that has been prepared by passing
hot air through a web including heat adhesive fibers so as to heat-bond
interlacing points between the fibers, the pressing process is performed
in a state in which the nonwoven fabric retains heat in a degree that
does not further promote the heat bonding.

3. The nonwoven fabric according to claim 1, wherein the planar element
having a plurality of apertures is a cylindrical roll that is used as a
rotational roll through which the nonwoven fabric is passed while being
pressed against the rotational roll, where the nonwoven fabric has been
prepared by passing hot air through the web including heat adhesive
fibers so as to heat-bond the interlacing points between the fibers.

4. The nonwoven fabric according to claim 1, wherein the web is a
laminate.

5. The nonwoven fabric according to claim 1, having a weight per unit of
15 to 60 g/m2 and a maximal thickness in the range of 0.2 to 5 mm.

6. The nonwoven fabric according to claim 1, wherein the difference in
the height between a convex part and an adjacent concave part on at least
one surface is in a range of 0.1 to 4.5 mm.

7. A molded member obtained by integrating the nonwoven fabric according
to claim 1 with an additional layer.

8. A product obtained by use of the nonwoven fabric according to claim 1.

9. A wiping cloth obtained by use of the nonwoven fabric according to
claim 1.

10. A product obtained by use of the molded member according to claim 7.

11. A wiping cloth obtained by use of the molded member according to
claim 7.

Description:

TECHNICAL FIELD

[0001] The present invention relates to a nonwoven fabric having a
concavo-convex surface structure and a product using the same. More
specifically, the present invention provides a nonwoven fabric with an
appearance having bulky hill parts filled with fibers and less bulky
plain parts, where the bill parts and the plain parts are intermingled on
the surface. The present invention further provides a nonwoven fabric
whose appearance provided with a concavo-convex surface can be changed
arbitrarily depending on the application, and also provides a fiber
product using the same.

BACKGROUND ART

[0002] For a method of producing a concavo-convex nonwoven fabric, a
heat-compressed nonwoven fabric formed by using an embossing roll is
widely known. However, since such a nonwoven fabric is formed by heat
compression, the bulk of the thus obtained concavo-convex nonwoven fabric
is rather low. The compressed part becomes like a film, and the feeling
of the thus obtained nonwoven fabric deteriorates. Even the remaining
parts other than the heat compressed part easily lose the bulkiness under
the influence of the heat compressing action.

[0003] An example of methods for increasing the bulkiness is implied by a
floor-cleaning sheet (see Patent document 1), which is produced by
laminating a fibrous web based on a heat-adhesive fiber and a mesh sheet
as a supporter, through which hot air is passed so as to integrate the
fibrous web and the mesh sheet thereby forming concaves and convexes.

[0004] However, when the region of the fibrous web for passing the hot air
is decreased due to the use of the mesh sheet, turbulence occurs in the
hot air in a region where the hot air does not pass through. This causes
some problems, for example, the accumulation of fibers in the web is
disordered. Adhesiveness is degraded at parts not passing the hot air,
and the nonwoven fabric strength deteriorates. Thus the shape of the
concave-convex and the area of the concaves are restricted.

[0005] In an alternative method disclosed for forming a concavo-convex
nonwoven fabric, a nonwoven fabric is prepared by partially
heat-compressing to join two layers by use of a heat-embossing roll,
where the first layer containing heat shrinkable fibers has a maximal
heat-shrinkage developing temperature that is lower than the melting
point of a second layer made of non-heat shrinkable fibers, and by
heating the nonwoven fabric to shrink the heat shrinkable layer so as to
form the concavo-convex nonwoven fabric (see Patent document 2).

[0006] In this case, the concave parts become film-like to some extent,
and thus the air permeability and the feeling deteriorate when the
concave area is increased. The feeling becomes rigid when the temperature
at the heating for shrinkage is higher than the melting point of the
unshrinkable fiber. On the other hand, when the temperature in heating is
equal or lower than the melting point of the unshrinkable fibers, the
feeling is improved, but problems occur, for example, the sufficient
strength cannot be obtained, and the dimensional stability of the
obtained nonwoven fabric is not satisfactory. Since the convex parts have
a lot of voids, the resistance against stress is inherently insufficient.

Prior Art Documents

Patent Documents

[0007] Patent document 1: JP 2003-230519 A

[0008] Patent document 2: JP 2006-45724 A

DISCLOSURE OF INVENTION

Problem to be Solved by the Invention

[0009] For solving the above-mentioned problems, an object of the present
invention is to provide a nonwoven fabric having a surface concavo-convex
structure that can be formed to have an arbitrarily concavo-convex shape
(providing concavo-convex shape), exhibits softness and high strength,
and has sufficient resistance against stress. Another object of the
present invention is to provide such a nonwoven fabric at a low cost.

Means for Solving Problem

[0010] The inventors of the present invention have made earnest studies so
as to solve the above-described problems. As a result, they found that
the problems can be solved by a product that is obtained by pressing an
element having a plurality of apertures against at least one surface of a
nonwoven fabric where the interlacing points between fibers have been
heat bonded by passing hot air through, and subsequently by removing the
element, and the inventors have completed the present invention on the
basis of this finding.

[0011] The present invention has the following configurations. [0012] (1)
A nonwoven fabric having a surface concavo-convex structure, formed by
pressing a planar element having a plurality of apertures against at
least one surface of a nonwoven fabric that has been prepared by passing
hot air through a web including heat adhesive fibers so as to heat-bond
interlacing points between the fibers, the pressing process is performed
in a state in which the nonwoven fabric retains heat in a degree that
does not further promote the heat bond. [0013] (2) The nonwoven fabric
according to the above (1), wherein the heat adhesive fibers are heat
adhesive conjugated fibers. [0014] (3) The nonwoven fabric according to
the above (1) or (2), wherein the planar element having a plurality of
apertures is a cylindrical roll that is used as a rotational roll through
which the nonwoven fabric is passed while being pressed against the
rotational roll, where the nonwoven fabric has been prepared by passing
hot air through the web including heat adhesive fibers so as to heat-bond
the interlacing points between the fibers. [0015] (4) The nonwoven fabric
according to any of the above (1) to (3), wherein the web is a laminate.
[0016] (5) The nonwoven fabric according to any of the above (1) to (4),
having a weight per unit (metsuke) of 15 to 60 g/mm2 and a maximal
thickness in the range of 0.2 to 5 mm. [0017] (6) The nonwoven fabric
according to any of the above (1) to (5), wherein the difference in the
height between a convex part and an adjacent concave part on at least one
surface is in a range of 0.1 to 4.5 mm. [0018] (7) A molded member
obtained by integrating the nonwoven fabric according to any of the above
(1) to (6) with an additional layer. [0019] (8) A product obtained by use
of the nonwoven fabric according to any of the above (1) to (6) or the
molded member according to the above (7). [0020] (9) A wiping cloth
obtained by use of the nonwoven fabric according to any of the above (1)
to (6) or the molded member according to the above (7).

EFFECTS OF THE INVENTION

[0021] The nonwoven fabric having a concavo-convex surface structure
according to the present invention has particularly bulky bill parts
(corresponding to convexes) and less bulky plain parts (corresponding to
concaves) that are intermingled, and thus it has bulkiness, and excellent
softness and strength. Furthermore, it has favorable air permeability,
and can be produced at a low cost.

BRIEF DESCRIPTION OF DRAWINGS

[0022] [FIG. 1] FIG. 1 is a partial plan view showing an example of a
planar element having a plurality of apertures used in the present
invention.

[0023] [FIG. 2] FIG. 2 includes diagrams showing an example of a molded
member of the present invention integrated with a web layer of polyester
fibers as an additional layer. FIG. 2A is a plan view showing the molded
member from the nonwoven fabric side having the surface concavo-convex
structure of the present invention, and FIG. 2B is a cross-sectional view
taken along a line A-A' in FIG. 2A.

[0024] [FIG. 3] FIG. 3 includes diagrams showing an example of a sanitary
napkin as a product of the present invention using the molded member as
shown in FIG. 2. FIG. 3A is a plan view showing the sanitary napkin from
the nonwoven fabric side having a surface concavo-convex structure of the
present invention, and FIG. 3B is a cross-sectional view taken along a
line B-B' in FIG. 2B.

DESCRIPTION OF THE INVENTION

[0025] A concavo-convex nonwoven fabric of the present invention is a
nonwoven fabric characterized in that bulky hill parts (corresponding to
convexes) and less bulky plain parts (corresponding to concaves) are
intermingled on the surface of the nonwoven fabric including heat
adhesive fibers.

[0026] Specifically, it is a nonwoven fabric having a concavo-convex
surface structure obtained by pressing a planar element having a
plurality of apertures against a nonwoven fabric prepared by passing hot
air through a web including heat adhesive fibers, in a state where the
nonwoven fabric retains heat in a degree that does not further promote
the heat adhesive of the nonwoven fabric.

[0027] An example of the heat adhesive fibers is a conjugated fiber having
a heat adhesive characteristic. The heat adhesive component of the heat
adhesive fiber is not limited particularly as long as it is a
thermoplastic resin component that melts due to heat when hot air is
passed through a web of the fibers, thereby forming bonding points. In
the present invention, the heat bonding points between fibers are formed
as a result of melting a thermoplastic resin component having a low
melting point with the hot air treatment. Examples of the resin
components for forming the heat adhesive fibers include polyolefin-based
resin (for example, polypropylene, a propylene copolymer [which is a
copolymer of propylene as main component and another α-olefin; the
examples include an ethylene-propylene binary copolymer, a
propylene-butene-1 binary copolymer, and a propylene-hexene-1 binary
copolymer], and polyethylene), polyester-based resin (for example,
polyethylene terephthalate), and polyamide-based resin (for example,
nylon-6). Specific examples of combinations of a low-melting point
component and a high-melting point component in a conjugated fiber
include a combination of polyethylene (low-melting point component) and
polypropylene (high-melting point component), and a combination of
polyethylene (low-melting point component) and polyethylene terephthalate
(high-melting point component) etc. From the viewpoint of bulkiness and
nonwoven fabric strength, a conjugated fiber of polyethylene and
polyethylene terephthalate is preferred in particular. Examples of the
conjugated fiber shape in the cross section perpendicular to the
longitudinal direction include a concentric core-sheath type, an
eccentric core-sheath type, a parallel type, a radial type and the like.
From the viewpoint of bulkiness, an eccentric core-sheath type is
preferred in particular. In the case of the concentric core-sheath type
or the eccentric core-sheath type conjugated fiber, the low-melting point
component forms the sheath component, and the high-melting point
component forms the core component.

[0028] The respective melting points of the low-melting point component
and the high-melting point component in the conjugated fiber can be
measured by differential scanning calorimetry.

[0029] Though the fineness of the heat adhesive fiber is not limited
particularly, a small fineness will be selected when the feeling is
valued highly, and the range is 0.5 dtex to 4 dtex, preferably 1 dtex to
3 dtex.

[0030] It is characteristic in particular that a bulky web can be used in
producing the nonwoven fabric of the present invention. In a conventional
method (the method as recited in the above Patent document 2), a
shrinkable fiber layer and an unshrinkable fiber layer are partially
joined and laminated, and the unshrinkable fiber layer is allowed to
protrude in the regions between the partial joints so as to develop a
concavo-convex shape in the fiber sheet by use of the shrinkage of the
shrinkable fiber layer. In the method, when the unshrinkable fiber layer
in use is bulky, a great stress is required to make it protrude (i.e., to
warp the unshrinkable fiber layer), and thus in some cases a sufficient
concavo-convex shape cannot be formed. In a forcible formation of the
concavo-convex shape, accompanied with the heat applied at the time of
heat shrinkage, the partial joints to integrate the both layers may be
destroyed as they cannot stand the stress caused by the protrusion and
warping. Thereby the layers may be peeled off.

[0031] In a method of forming convexes and concaves with a conventional
heat embossing roll (an embossing roll denotes an apparatus provided with
a roll having convex-concave pattern formed on the surface, which can
compress and bond a web with heat by use of a combination of the
embossing roll and a flat roll, or a combination of an embossing roll and
another embossing roll), when a bulky web is used, it is necessary to
engrave the embossing roll to have a deeply embossed pattern with a great
difference in height between a convex and a concave. In particular, when
the distance between pitches of the convexes is relatively long, even if
the concaves are engraved deep, the web will contact the concaves of the
embossing roll. From the viewpoint of the cost for the engraving, use of
a bulky web will have various limitations in this method.

[0032] When a heat embossing roll is used, the convexes of the embossing
roll are transcribed to the nonwoven fabric so as to form a compressed
part. In this case, for obtaining a high nonwoven fabric strength, it is
required to increase the area of the compressed part. Since the heat
embossed part becomes like a film due to heat compression and the voids
of the entire nonwoven fabric are decreased, the feeling and the air
permeability deteriorate considerably, namely, it is difficult to balance
the strength with the feeling.

[0033] However, in the present invention, the convexes formed on the
nonwoven fabric surface are not pressed against the planar element base
at the apertures of the planar element having apertures. Therefore,
during a process of forming the convexes, the sites are free toward the
upper space in the thickness direction of the nonwoven fabric (i.e., the
sites are not suppressed to decrease its bulk). As a result, even when
the web in use is particularly bulky, there is no difficulty in
production of a nonwoven fabric having a concavo-convex surface
structure. In the present invention, the term "apertures" in a planar
element having apertures denotes through holes in the direction from the
surface to back face of the planar element. Although the sites where the
convexes are formed are free toward the upper space, since the heat
adhesive conjugated fibers forming this site have been heat-bonded at the
interlacing points, even in the process of forming the convex parts, the
integrity as the fiber layer will not be sacrificed particularly at the
convex parts. Shedding of fibers or fluffing will not occur at the sites.
Similarly at the concave parts, although compressed parts are formed as a
result of pressing the planar element, since the process of pressing the
planar element is performed in a state where the nonwoven fabric retains
heat in a degree that does not further promote the heat bonding, a
heat-compressed structure is not provided unlike the case of using a heat
embossing roll, and thus even the compressed part can maintain a
comparatively high percentage of voids. Furthermore, regardless of
heating of the embossing roll, in a product formed by pressing with an
embossing roll, the compressed parts are scattered. In contrast, the
compressed parts according to the present invention surround the convex
parts and form a network linked on the nonwoven fabric surface. Due to
this structure, even though the strength at a compressed part formed
between a pair of convex parts adjacent to each other is poorer than that
at a compressed part formed by using an embossing roll, the nonwoven
fabric as a whole can have excellent strength. Since appropriate voids
are retained, the feeling and the air permeability are not sacrificed
while a high strength is exhibited.

[0034] From the viewpoint of clarifying the convex parts of the nonwoven
fabric, it is preferable that the weight per unit of the web in use is in
a range of 15 to 60 g/m2, and it is particularly preferable that the
weight per unit is in a range of 20 to 35 g/m2. From the viewpoint
of the bulkiness, it is preferable that the apparent specific volume is
in a range of 20 to 70 cm3/g, and it is particularly preferable that
the apparent specific volume is in a range of 25 to 60 cm3/g.

[0035] In the web used in the present invention, fibers other than a
so-called heat adhesive fibers (hereinafter, referred to as "non-heat
adhesive fibers") may be blended. Examples of the non-heat adhesive
fibers include natural fibers (wood fibers and the like), regenerated
fibers (rayon and the like), semi-synthetic fibers (acetate and the
like), chemical fibers and synthetic fibers (polyester, acrylic, nylon,
vinyl chloride and the like). The term "non-heat adhesive fibers" in the
present invention denotes fibers that do not cause a thermal conversion
(melting or softening) relating to heat adhesion under a condition of hot
air treatment when the blended non-heat adhesive fibers are subjected to
the hot air treatment together with the heat adhesive fibers. Therefore,
these fibers may be regular fibers (single fibers) or conjugated fibers
as long as the above conditions are met.

[0036] Though it is difficult to define the blend ratio of the non-heat
adhesive fibers since the ratio varies depending on the types of the
fibers in use and/or the desired performance of the nonwoven fabric, the
ratio of these non-heat adhesive fibers is 5 to 90 wt %, or more
preferably 10 to 60 wt % with regard to the total weight of the web. The
web used in the present invention may be a laminate including any other
layers that can permeate hot air as long as the desired effects of the
present invention including the convex-concave formation and
processability are not inhibited. The examples include fiber layers
(e.g., fibrous web, nonwoven fabric, woven fabric and knitted fabric), a
punched sheet and a porous film. The layer for lamination has a melting
point higher than the temperature of the hot air. Bonding with the other
layer may be performed by any techniques such as an air-through method, a
needle-punching method, a water-stream interlacing method, heat
compression, adhesion with an adhesive, and adhesion using a hot-melt
adhesive, as long as the features of the nonwoven fabric having the
surface concavo-convex structure according to the present invention are
not sacrificed excessively. In general, lamination using a hot-melt
adhesive is preferred.

[0037] For producing a nonwoven fabric where the interlacing points
between fibers are heat-bonded by passing hot air through a web including
the heat adhesive fibers, for example, an ordinary hot air processor
(suction band dryer) can be used for the purpose of hot air treatment
under an ordinary condition. In general, a hot air processor is used to
blow hot air at a certain temperature to a web fed onto an automotive
conveyer net and at the same time to draw the hot air passing through the
web from the bottom of the conveyer net. The processor is suitable for
processing the heat adhesive conjugated fibers so as to make a bulky
nonwoven fabric.

[0038] The temperature of the hot air is not limited in particular as long
as the heat adhesive fibers bond sufficiently to each other by heat at
the interlacing points. Preferably, the hot air treatment is performed at
a temperature higher by a range of 1 to 10° C. than the melting
point of the resin components of the heat adhesive fibers. From the
viewpoint of bulkiness, it is preferable to perform the hot air treatment
at a temperature higher by a range of 1 to 5° C. than the melting
point of the low-melting point resin component and lower by a range of 10
to 30° C. than the melting point of the high-melting point resin
component. Therefore, a conjugated fiber where the difference in the
melting points between the low-melting point resin component and the
high-melting point resin component is 11 to 35° C. is used
preferably.

[0039] A planar element having a plurality of apertures is pressed against
at least one surface of the nonwoven fabric where the interlacing points
between fibers have been heat-bonded by hot air, and subsequently, the
planar element is removed to obtain a nonwoven fabric having a surface
concavo-convex structure. Though it is also possible to provide the
concavo-convex shape by pressing a flat plate having a plurality of
apertures, from the viewpoint of workability, it is preferable that the
concavo-convex shape is provided to the nonwoven fabric where the
interlacing points between the fibers have been heat bonded, by pressing
the nonwoven fabric through at least one rotational roll having on its
surface a plurality of apertures. The time for pressing is not limited
particularly as long as the concavo-convex shape is provided
sufficiently. In a case of using a rotational roll having a plurality of
apertures on the surface. The rotational rate of the roll can be set to a
range of 1 to 100 m/min., although the rate is not limited to this
example in particular. In an example of the method, a nonwoven fabric
where the interlacing points between the fibers of web have been
heat-bonded is prepared by using a hot air circulation heat processor.
Subsequently, a rotational roll having a plurality of apertures on the
surface is set on a conveyer placed next (exit) to the processor, so that
the nonwoven fabric is passed between the conveyer and the rotational
roll having a plurality of apertures on the surface. Thereby, the pattern
of the apertures of the roll is transcribed on the nonwoven fabric and
the concavo-convex structure is formed on the nonwoven fabric.

[0040] The pressure for pressing the planar element having a plurality of
apertures against the nonwoven fabric can be selected arbitrarily as long
as the pressure is sufficient to form the concavo-convex shape and to
prevent excess compression of the concaves, taking the shape and the
nature of the nonwoven fabric into consideration. A preferred range is
0.098 MPa to 2.0 MPa. A range of 0.2 MPa to 1.0 MPa is preferred further
from the viewpoint of preventing excessive compression of the concaves.
This holds true for a roll-type planar element. It is also possible to
use a flat plate in place of the roll as the planar element.
Alternatively, a curved plate may be used as a planar element so that the
object of the present invention can be achieved easily. When a roll-like
planar element is used as a rotational roll, the roll may have rod-like
supportive members at both ends in the longitudinal direction of the
roll, and the supportive members extend from the rotational bearing at
the center of the roll cross section radially in the roll's plane just
like a spoke of a bicycle. An alternative roll may have a disk having at
the center a hole for bearing, and the disk is implanted at the both ends
in the longitudinal direction of the roll. Needless to note, in such a
case, the rod-like supportive member or the disk will be arranged at a
position so as not to block the apertures formed on the roll curved
surface from the interior of the roll. Normally, the length of the roll
is set to be longer than the width of the nonwoven fabric whose
interlacing points have been heat-bonded, so that the rod-like supportive
member or the disk will be provided outside the width of the nonwoven
fabric. However, the present invention is not limited to this example.

[0041] In the pressing process with the planar element having a plurality
of apertures, it is preferable that a melt other than the heat bonding in
the previous step of hot air treatment does not occur in the nonwoven
fabric. On the other hand, care should be taken such that the concave
structure compressed by the pressing process does not recover its
original unpressed state. For this purpose, in the pressing process, it
is preferable that the nonwoven fabric is heated to a degree that avoids
the heat melting, namely, to a degree that does not promote the further
heat bonding in the nonwoven fabric. It is not necessary that the planar
element having a plurality of apertures be heated during the pressing
process. However, it is preferable that the pressing process is performed
while the heat applied in the preceding hot air treatment remains in the
nonwoven fabric. In a case of heating a planar element having a plurality
of apertures (in a case where sufficient heat is not retained in the
nonwoven fabric or in a case where the pressing process is performed
after the nonwoven fabric is cooled down), the planar element may be
heated during the pressing process to a temperature not to cause heat
melt in the fibers of the nonwoven fabric. In such a case, it is
preferable that the temperature of the nonwoven fabric is 50° C.
or higher and lower by at least 5° C. than the melting point of
the heat adhesive fiber (or the melting point of the low-melting point
component of a conjugated fiber). Further, for a temperature for
preventing excessive compression of the concaves, a temperature of
60° C. or higher and lower by at least 10° C. than the
melting point of the heat adhesive fiber is preferred. It is particularly
preferable that the temperature is 70° C. or higher and lower by
at least 20° C. than the melting point of the heat adhesive fiber.
When the temperature of the warmed nonwoven fabric is lower by at least
5° C. than the melting point of the heat adhesive fiber, the less
bulky plain parts will not become like a film. When the temperature is
50° C. or higher, the less bulky plain parts will not recover its
original unpressed state, and thus the clear concavo-convex structure can
be maintained. In this context, "the planar element is heated" includes a
state where the heat remaining in the web is conducted to the planar
element during the process of pressing to the web, and as a result, the
planar element retains heat sufficient to provide the concavo-convex
structure to the nonwoven fabric.

[0042] Therefore, in the present invention, "(be) performed in a state . .
. retains heat" in the context of "the pressing process is performed in a
state where the nonwoven fabric retains heat in a degree that does not
promote further heat bonding in the nonwoven fabric" indicates that the
nonwoven fabric itself is maintained at the above-mentioned temperature.
Alternatively, the planar element itself has been heated so that the heat
remaining in the web is conducted to the planar element during the
process of pressing the web, and as a result, the pressing process is
performed in a state where the planar element retain heat sufficient to
provide the concavo-convex structure to the nonwoven fabric.

[0043] The planar element for the pressing process is not limited in
particular as long as it has apertures, for example. It is not limited to
the roll as mentioned above, but can be a plate (a flat plate or a curved
plate). The planar element may be arranged at the exit of the hot air
processor or may be arranged during any of the following process steps.
It is preferable that the temperature of the nonwoven fabric at the time
of pressing the nonwoven fabric with the planar element is in the
above-mentioned range From the viewpoint of energy efficiency, it is
preferable that the planar element is not heated affirmatively, but hot
air is passed through the web at the time of heat bonding the interlacing
points of the fibers and the heat applied to the nonwoven fabric at that
time is used for the pressing process. In this case, the distance from
the exit of the hot air processor to the entrance of the presser (planar
element) is set to maintain the temperature of the nonwoven fabric.

[0044] In the planar element having a plurality of apertures, the shape of
each aperture may be varied, for example, a circle, a square, a hexagon,
an ellipse, a rectangle, a rhombus, a cross and the like, without any
particular limitations. The dimension of one aperture is preferably in a
range of 7 to 150 mm2, and the arrangement can be selected
arbitrarily for example, a parallel arrangement, a staggered arrangement,
an irregular arrangement and the like. From the viewpoint of the nonwoven
fabric strength, the staggered arrangement is preferred.

[0045]FIG. 1 is a partial plan view showing an example of a planar
element having a plurality of apertures used in the present invention. A
planar element 1 in FIG. 1 has circular apertures 2. A staggered
arrangement of the apertures denotes a pattern as shown in FIG. 1 where
the apertures a, b, and c are formed to define apices of a substantially
equilateral triangle, and the equilateral triangle is repeated at a
constant pitch. However, the present invention is not limited to this
example.

[0046] Regarding a planar element having a plurality of apertures, the
apertures make bulky hill parts (convexes) in the obtained nonwoven
fabric having a concavo-convex surface structure, and the continuous
plane between the apertures makes a less bulky plain part (concave). It
is preferable that the porosity of the apertures in the planar element at
the site to get contact with the nonwoven fabric is in a range of 10 to
90%, and more preferably, in a range of 20 to 80%. The surface area of
the less bulky plain part may be decreased to obtain a softer nonwoven
fabric, and the porosity can be varied arbitrarily in accordance with the
application and the object.

[0047] The material of the planar element is not limited in particular as
long as it can stand the loads such as heating and pressure provided by
the pressing or the like as mentioned above. The examples include
stainless steel (SUS) and aluminum. From the viewpoint of heat resistance
and pressure resistance, SUS is used preferably. There are not any
particular limitations on the thickness and dimension of the planar
element.

[0048] The weight per unit of the nonwoven fabric having the surface
concavo-convex structure is preferably in a range of 15 g/m2 to 60
g/m2. More preferably, it is 15 g/m2 to 50 g/m2, and
further preferably, 15 g/m2 to 30 g/m2.

[0049] Further, the thickness of the nonwoven fabric having the surface
concavo-convex structure is not limited particularly. It is preferable
that the thickness at the thickest sites (convexes) is in a range of 0.2
to 5 mm. It is further preferable that the difference in height between a
convex on at least one surface and the adjacent concave is in a range of
0.1 to 4.5 mm. The means for providing a surface concavo-convex structure
to a nonwoven fabric in the present invention is characterized in
particular in its excellent feature of providing a concavo-convex shape
to a bulky web. As a result, a nonwoven fabric that is relatively thick
and bulky and that has a large difference between the convexes and
concaves can be obtained in an efficient manner.

[0050] It is also possible to laminate a fiber layer, a sheet, a film and
the like on the nonwoven fabric having the surface concavo-convex
structure, and integrate to form a molded member as long as the effect of
the present invention is not affected. The fiber layer (fibrous web,
nonwoven fabric, woven fabric, knitted fabric and the like) includes wood
fibers such as cotton and linen, natural fibers, chemical fibers such as
rayon and acetate, and synthetic fibers such as polyolefin, polyester,
acrylic, nylon, vinyl chloride and the like. In this case, the additional
layer may be integrated with the concavo-convex surface of the nonwoven
fabric having the surface concavo-convex structure, or may be integrated
with the other surface. The processes for integration include an
air-through method, a needle-punching method, a waterstream interlacing
method and a hot melt bonding method that uses a hot-melt adhesive,
though the present invention is not limited to these examples.

[0051] For example, by laminating a web of polyester fibers with the
concavo-convex nonwoven fabric and integrating, some effects are
obtained, for example, a molded member with high cushioning properties
can be obtained.

[0052] The product using the molded member can be used for hygienic goods
and industrial materials. For example, for a hygienic good, the product
is used as a top sheet of a sanitary napkin or a surface material of a
disposable diaper so that the concavo-convex part will make the surface
in contact with skin. As a result, appropriate spacing can be held
between the nonwoven fabric and the skin, and possibly rash caused by
menstrual blood or urine can be prevented. When the product is applied to
industrial materials to make packing materials and soundproof sheets,
cushioning effects or sound-absorbing effects due to the convexes and the
concaves can be expected.

[0053] Furthermore, due to the scraping effect (scraping at the convexes
and collecting at the concaves) provided by the concavo-convex parts, the
product may be used preferably as a wiping cloth. Therefore, when the
product is laminated with any other members, for example, when the
product is arranged so that the convexes and the concaves on a top sheet
of a sanitary napkin or a surface material of a disposable diaper will be
in contact with the skin, or when the product is used as a wiping cloth
member for its scraping effect of the convexes and the concaves, the
other member will be laminated on the surface of the nonwoven fabric
opposite to the surface on which the convexes and the concaves have been
formed. In a case where the convexes and the concaves in the nonwoven
fabric of the present invention are formed on the both surface of the
nonwoven fabric, the additional member will be laminated on any one of
the surfaces. Needless to note, the nonwoven fabric of the present
invention may be used as a wiping cloth without laminating any other
members.

[0054] FIG. 2 shows an example of a molded member obtained by laminating
an additional layer on the nonwoven fabric of the present invention. FIG.
2A is a plan view showing the member from the nonwoven fabric side having
the surface concavo-convex structure of the present invention, and FIG.
2B is a cross sectional view taken along the line A-A' in FIG. 2A.

[0055] The molded member as shown in FIG. 2 is obtained by integrating a
nonwoven fabric 5 having the surface concavo-convex structure according
to the present invention and a web layer 6 of polyester fibers by use of
a hot melt adhesive 7 or the like. The cushioning properties provided by
the lower layer of polyester fibers are conducted to the surface
concavo-convex structure on the upper layer. For example, when the
nonwoven fabric is used as a wiping cloth, the scraping effect is
improved due to the cushioning properties. When it is used as a surface
material of sanitary goods such as sanitary napkins, the appropriate skin
contact due to the surface concavo-convex structure serves to prevent
rash and the lower layer provides cushioning properties to improve the
feeling. Numeral 3 denotes convexes parts) and 4 denotes a concave (plain
part) of a nonwoven fabric having the surface concavo-convex structure of
the present invention.

[0056] FIG. 3 shows a sanitary napkin as an example of a product formed by
using the molded member as the surface material. FIG. 3A is a plan view
showing the product from the nonwoven fabric side having the surface
concavo-convex structure of the present invention. FIG. 3B is a
cross-sectional view taken along the line B-B' in FIG. 3A.

[0057] Numeral 10 denotes a surface material of the molded member as shown
in FIG. 2, which is a liquid-permeable surface covering that passes body
fluids such as blood. Numeral 11 is a liquid absorbing layer (for
example, it is composed of a mixture layer of pulp and polymer absorbent)
enveloped with a tissue paper 14. Further, a liquid impermeable back
sheet 12 is arranged on the rear side so as to prevent the absorbed body
fluids from leaking outside. Further, water-repelling side sheets (it is
called also "side gathers") 13 are provided at both sides of the
water-absorbing article for preventing leakage of the absorbed liquid
such as the body fluids. Though not shown in the attached drawings, each
of the members is heat bonded at appropriate sites by use of a hot melt
adhesive or the like so that they will not drop out. In FIG. 3B, at the
both lateral ends of the molded member 10 (shown with the sign `a`), only
the both lateral ends of the molded member in FIG. 2B are composed of the
web layer 6 alone on which the nonwoven fabric 5 having the surface
concavo-convex structure is not laminated.

[0058] The molded member shown in FIG. 2 can be used favorably also as the
surface material of a disposable diaper similarly to the case of the
sanitary napkin as shown in FIG. 3, although the diaper is not shown in
any drawings.

[0059] Hereinafter, the present invention will be described in detail with
reference to EXAMPLES, though the present invention is not limited to the
EXAMPLES.

<Nonwoven Fabric Strength>

[0060] The strength of the nonwoven fabric is calculated in compliance
with the tensile test defined in JIS L1906 (revised on Feb. 20, 2000) by
using "Autograph AG500D (trade name)" manufacture by SHIMADZU. The sample
for measuring the strength is prepared by cutting a nonwoven fabric to be
150 mm in the direction that the fibers are aligned (MD direction) and 50
mm in the crossing direction (CD direction). The strength was measured at
a tensile rate of 100 mm/min. and a holding length of 100 mm.

<Bulkiness>

[0061] The weight per unit of the sample (weight per square meter; in
fact, a sample weight of 100×100 mm was measured and the value was
converted) was measured (w), and the thickness of the sample was measured
(t) under the condition of loading of 2 gf/cm2 (196 Pa) and
measurement rate of 2 mm/sec. by using "Digi-Thickness Tester" (trade
name) manufactured by TOYO SEIKI SEISAKUSHO, LTD. The apparent specific
volume (v) was calculated by use of the equation below.

v=t/w1000 (cm3/g) (Equation)

A higher value of the apparent specific volume (v) indicates that the
sample is bulky.

[0062] The thickness was measured by using "Digi-Thickness Tester (trade
name)" manufactured by TOYO SEIKI SEISAKUSHO, LTD under a condition of
loading of 2 gf/cm2 (196 Pa) and measurement rate of 2 mm/sec. The
measurement sample was cut into a 10×10 cm piece and measured at
six sites.

<Difference in Height Between Convex Part on Nonwoven Fabric Surface
and Adjacent Concave Part)

[0063] A nonwoven fabric was sectioned in a direction crossing the planar
direction of the nonwoven fabric along a line passing through the center
of the convex part, namely, so-called thickness direction. The cross
section was subjected to a measurement using a digital microscope
(VHX-900) manufactured by KEYENCE so as to measure the thickness at the
concave part and the convex part. Measurement was conducted at ten sites
so as to obtain the average.

Example 1

[0064] Heat adhesive concentric sheath-core type conjugated fibers were
prepared. For the sheath, a low-melting point component of polyethylene
(melting point: 130° C., melt mass flow rate: 16 g/10 min.) was
used, and for the core, a high-melting point component of polypropylene
(melting point: 160° C., melt mass flow rate: 20 g/10 min.) was
used. The sheath and the core were arranged at a ratio of 50/50 in
weight, and the fibers had fineness of 2.2 dtex and a cutting length of
51 mm. The fibers were made into a web of 25 g/m2 (weight per unit)
by a carding method. Interlacing points between the fibers of the web
were bonded by passing hot air through the web by use of a 130° C.
hot air circulation suction band dryer. Immediately after this bonding,
the thus obtained nonwoven fabric was passed at a rate of 8.5 m/min.
through a porous roll made of stainless steel and having porosity of
22.7%. The porous roll had circular staggered apertures 5 mm in diameter.
In an observation through infrared thermography, the nonwoven fabric
temperature at the time of passing through the roll was 70° C.,
the temperature of the porous roll was 70° C., and the pressure
applied to the nonwoven fabric by the porous roll was 0.3 MPa. The
obtained concavo-convex nonwoven fabric had a weight per unit of 25
g/m2, the maximal thickness was 0.75 mm, and the difference in
height between the convex and the concave was 0.5 mm. As the apparent
specific volume was 30 cm3/g, the nonwoven fabric was bulky, and the
strength was as high as 73 N/5 cm×21 N/5 cm (MD×CD).

Example 2

[0065] Heat adhesive concentric sheath-core type conjugated fibers were
prepared. For the sheath, a low-melting point component of polyethylene
(melting point: 130° C., melt mass flow rate: 16 g/10 min.) was
used, and for the core, a high-melting point component of polyester
(melting point: 250° C., intrinsic viscosity: 0.63) was used. The
sheath and the core were arranged at a ratio of 60/40 in weight, and the
fibers had fineness of 2.2 dtex and a cutting length of 51 mm. The fibers
were made into a web of 25 g/m2 (weight per unit) by a carding
method. Interlacing points between the fibers of the web were bonded by
passing hot air through the web by use of a 130° C. hot air
circulation suction band dryer. Immediately after this bonding, the thus
obtained nonwoven fabric was passed at a rate of 8.5 m/min. through a
porous roll having porosity of 48.6%. The roll had elliptic staggered
apertures (10 mm (transverse)×30 mm (longitudinal)). The nonwoven
fabric temperature at the time of passing through the roll was 70°
C., the temperature of the porous roll was 70° C., and the
pressure applied to the nonwoven fabric by the porous roll was 0.3 MPa.
The obtained concavo-convex nonwoven fabric had a weight per unit of 25
g/m2, the maximal thickness was 1.38 mm, and the difference in
height between the convex part and the concave part was 0.87 mm. As the
apparent specific volume was 55 cm3/g, the nonwoven fabric was
bulky, and the strength was as high as 59 N/5 cm×17 N/5 cm
(MD×CD).

Comparative Example 1

[0066] Heat adhesive concentric sheath-core type conjugated fibers were
prepared. For the sheath, a low-melting point component of polyethylene
(melting point: 130° C., melt mass flow rate: 16 g/10 min.) was
used, and for the core, a high-melting point component of polypropylene
(melting point: 160° C., melt mass flow rate: 20 g/10 min.) was
used. The sheath and the core were arranged at a ratio of 50/50 in
weight, and the fibers had fineness of 2.2 dtex and a cutting length of
51 mm. The fibers were made into a web of 25 g/m2 (weight per unit)
by a carding method. The web was pressed at pressure of 1.96 MPa and at a
rate of 6 m/min. with upper and lower rolls at 124° C. The rolls
were emboss/flat heat compression rolls having rhombus convexes and whose
emboss area rate was 23%. The obtained concavo-convex nonwoven fabric had
a weight per unit of 25 g/m2, the maximal thickness was 0.3 mm, and
the difference in height between the convex part and the concave part was
0.2 mm. Though the obtained nonwoven fabric exhibited a strength as high
as 55 N/5 cm×24 N/5 cm (MD×CD), the apparent specific volume
was 12 cm3/g, namely, the bulkiness was considerably inferior, and
the feeling was rigid.

Comparative Example 2

[0067] For a plain weave mesh sheet, a net 10 mm in the yarn spacing and
13 g/m2 in the basic weight was used. A low-melting point component
of polyethylene (melting point: 130° C., melt mass flow rate: 16
g/10 min.) was used and for the core, a high-melting point component of
polyester (melting point: 250° C., intrinsic viscosity: 0.63) was
used. The sheath and the core were arranged at a ratio of 60/40 in weight
to form a heat adhesive concentric sheath-core type conjugated fiber
having a fineness of 2.2 dtex and a cutting length of 51 mm. The heat
adhesive concentric sheath-core type conjugated fibers were made to a web
having a weight per unit of 25 g/m2, by a carding method. The web as
an upper layer is stacked on the net, to which hot air was applied by
using a 130° C. hot air circulation type suction band dryer so as
to be integrated. The thus obtained nonwoven fabric had a weight per unit
of 35 g/m2, and the apparent specific volume was as low as 23
cm3/g. Furthermore, since the hot air does not pass through the
regions where the net was integrated, the accumulation of fibers becomes
irregular and the bonding between fibers was insufficient, and the
strength of the obtained nonwoven fabric was as low as 22.5 N/5 cm.

INDUSTRIAL APPLICABILITY

[0068] A nonwoven fabric and a molded member of the present invention,
having bulky hill parts (convexes) and the plain parts (concaves) are
intermingled on the nonwoven fabric surface, are bulky and have an
excellent softness. Due to the effect of scraping (wiping) soils and the
favorable feeling/touch, they can be used preferably for a baby wipe and
a wiping cloth. Furthermore, due to the excellent bulkiness and softness,
they can be used for absorbing articles such as a top sheet or a second
sheet of a disposable diaper or a sanitary napkin.